US4010303A - Tufted carpet with woven ribbon backing of polyamide and polyester - Google Patents

Tufted carpet with woven ribbon backing of polyamide and polyester Download PDF

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Publication number
US4010303A
US4010303A US05/676,845 US67684576A US4010303A US 4010303 A US4010303 A US 4010303A US 67684576 A US67684576 A US 67684576A US 4010303 A US4010303 A US 4010303A
Authority
US
United States
Prior art keywords
carpet
polyamide
polyester
backing
tufted carpet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US05/676,845
Inventor
Otto Ramsauer
Heribert Dau
Willi Gumbmann
Ulrich Schulze
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Akzona Inc
Original Assignee
Akzona Inc
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Filing date
Publication date
Application filed by Akzona Inc filed Critical Akzona Inc
Application granted granted Critical
Publication of US4010303A publication Critical patent/US4010303A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/12—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyamide as constituent
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D05C17/023—Tufted products characterised by the base fabric
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]

Definitions

  • the invention relates to a tufted carpet with a backing made of ribbon-shaped warp and weft yarns.
  • carpets consisting of essentially the backing, the pile and an adhesive coating which is used to anchor the pile in the backing.
  • Woven fabrics are frequently used for carpet backing.
  • the object of the innovation is to make a tufted carpet with a backing of ribbon-shaped warp and filling yarns of synthetic polymers, and pile yarns of polyamide, characterized by warp and filling yarns having a matrix-fibrillar structure made from a blend of 65 to 80 weight percent polyamide and 20 to 35 weight percent polyester.
  • Warp and filling yarns consist preferably of a mixture of 70 to 80 weight percent polyamide and 20 to 30 weight percent polyester.
  • Eminently suitable are such matrix-fibrillar structures with fibrils having a length between about 0.5 and 160 microns, preferably between 1.5 and 80 microns, and a diameter between 0.5 and 6, preferably between 0.5 and 1.5 microns.
  • Polyethylene terephthalate is especially suited as polyester.
  • polyester in the mixture is also composed of a mixture of two different polyesters.
  • Eminently suitable within the framework of the innovation are delustered warp and filling yarns.
  • the delusterant content e.g., titanium dioxide, may, e.g., be between 0.05 and 0.4%.
  • the matrix-fibrillar structure of the innovation is understood to refer to internal structures of molded elements of polymer mixtures, whereby one component forms a coherent structure, the so-called matrix, in which another component is embedded in the form of discontinuous fibrils or microfibers. Structures of this type are mentioned, e.g., in U.S. Pat. No. 3,704,191, Col. 5, paragraph 3. According to the innovation, the matrix is composed of polyamide.
  • the ribbons within the framework of the innovation have a lower splitting capacity or tendency; in other words, they do not simply break down into so-called split fiber structures or reticular structures under mechanical stressing. On the other hand, they do not offer high enough a resistance to the needles to cause tufting problems. Thus, in backings for tufted carpets, the ribbons have a much greater stability than propylene ribbons and do not tear in longitudinal direction.
  • Ribbon-shaped yarns as provided by the innovation in tufted carpets, can be obtained, e.g., as follows. Dried chips of polyamide and polyester are mixed in an appropriate ratio and extruded to films. The polyester and polyamide can also be melted separately and the two melts can be mixed and made into film. Subsequently, the film can be slit to the desired width and the resulting ribbons are drawn. It is also possible first to draw the film and then slit the latter into ribbons. Drawing is accomplished preferably at temperatures above 100° C., a suitable drawing ratio is 1:3 to 1:5, but higher draw ratios may be selected. The thickness of the drawn ribbons may vary within relatively wide limits. Thicknesses between 25 and 50 microns are especially suitable.
  • the tufted carpet is produced according to well-known processes, whereby appropriate backing fabrics of ribbon-shaped material according to the innovation, and conventional latex and pile yarns of polyamide are used.
  • the tufting process as such is known and need not be explained in further detail.
  • the pile material consists of conventional polyamides, such as nylon 6 or nylon 66. Conventional latices can be used as latex.
  • the tufted carpet may have another, heavier, secondary backing which improves the anchoring of the pile yarn and which may, especially, increase the weight of the carpet.
  • Tufted carpets according to the innovation have a very level appearance, which is of particular benefit in patterned carpets. This improved evenness shows up in patterns obtained by dyeing methods as well as in patterns produced by using tufts of different heights.
  • the tufted carpet according to the innovation has a high dimensional stability. There is a good bond between latex and backing and pile material.
  • the tufting material according to the innovation is very readily flattened and covered. Difficulties in piece-dyeing in the form of bleeding or non-dyeing of the backing are practically non-existent.
  • the tufted carpet according to the invention can also be dyed directly in the form of long strips on continuous dye equipment. The notorious floating often observed with carpet strips with a polypropylene backing is not encountered.
  • a mixture of chips of 80% polyamide and 20% polyethylene terephthalate is dried and a film is cast therefrom using a single-screw extruder with a 400 mm. wide extruding die. Subsequently, the film is slit into ribbons and drawn to a ratio of 1:3.6.
  • the ribbons serve to weave a backing fabric in plain weave.
  • a greige carpet is produced by the known needle tufting technique by insertion of a polyamide pile material using a Singer Cobble Tufting machine of conventional design and gauge, which greige carpet is then conventionally dyed with acid dyes on a winch vat, then extracted, dried and provided with a coating to anchor the pile, which coating is simultaneously the adhesive for a jute laminate.
  • the tufting support material is dyed the same shade as the pile material.

Abstract

A tufted nylon carpet having ribbon-shaped warp and filling yarns made from a mixture of 65 to 80 weight percent polyamide and 20 to 35 weight percent polyester. The yarns of the fiber exhibit a reduced tendency to split and the carpet has high dimensional stability and a very level appearance.

Description

BACKGROUND OF THE INVENTION
The invention relates to a tufted carpet with a backing made of ribbon-shaped warp and weft yarns.
Most of the carpets currently being produced are so-called carpets consisting of essentially the backing, the pile and an adhesive coating which is used to anchor the pile in the backing. Woven fabrics are frequently used for carpet backing.
The manufacture of jute carpet backings for tufted carpets is known. One drawback of carpets embodying such backing fabric is the relatively high sensitivity to moisture, since in the presence of water the jute backing will be subjected to a comparatively high shrinkage. Moreover, such jute tufting backings exhibit a relatively high bleeding tendency so that the same colors may produce considerable shade variations in piece-dyeing of different lots. Since jute yarns need in most cases to have a relatively high twist, there is not infrequently during tufting a formation of streaks or so-called gaps, as the tufting needles are deflected, which impairs the appearance of the carpet.
It is also known how to manufacture carpet backings from ribbon-shaped warp and filling yarns of synthetic polymers, whereby the synthetic material being most frequently used is polypropylene. The drawback encountered in using polypropylene for the warp and filling is that the carpet backings cannot be dyed or only very unsatisfactorily so, and that after dyeing of the carpet the light color of the backing grins through the pile of the carpet. Polypropylene carpet backings are, moreover, lacking dimensional stability and tend to creep. Polyamide or polyester ribbons in the carpet backing have the added drawback that needle deflection in tufting is relatively frequent causing the carpet to have an uneven appearance.
DESCRIPTION OF THE INVENTION
The object of the innovation is to make a tufted carpet with a backing of ribbon-shaped warp and filling yarns of synthetic polymers, and pile yarns of polyamide, characterized by warp and filling yarns having a matrix-fibrillar structure made from a blend of 65 to 80 weight percent polyamide and 20 to 35 weight percent polyester. Warp and filling yarns consist preferably of a mixture of 70 to 80 weight percent polyamide and 20 to 30 weight percent polyester. Eminently suitable are such matrix-fibrillar structures with fibrils having a length between about 0.5 and 160 microns, preferably between 1.5 and 80 microns, and a diameter between 0.5 and 6, preferably between 0.5 and 1.5 microns. Polyethylene terephthalate is especially suited as polyester. It is also advantageous when the polyester in the mixture is also composed of a mixture of two different polyesters. Eminently suitable within the framework of the innovation are delustered warp and filling yarns. The delusterant content, e.g., titanium dioxide, may, e.g., be between 0.05 and 0.4%.
The matrix-fibrillar structure of the innovation is understood to refer to internal structures of molded elements of polymer mixtures, whereby one component forms a coherent structure, the so-called matrix, in which another component is embedded in the form of discontinuous fibrils or microfibers. Structures of this type are mentioned, e.g., in U.S. Pat. No. 3,704,191, Col. 5, paragraph 3. According to the innovation, the matrix is composed of polyamide.
The ribbons within the framework of the innovation have a lower splitting capacity or tendency; in other words, they do not simply break down into so-called split fiber structures or reticular structures under mechanical stressing. On the other hand, they do not offer high enough a resistance to the needles to cause tufting problems. Thus, in backings for tufted carpets, the ribbons have a much greater stability than propylene ribbons and do not tear in longitudinal direction.
Ribbon-shaped yarns, as provided by the innovation in tufted carpets, can be obtained, e.g., as follows. Dried chips of polyamide and polyester are mixed in an appropriate ratio and extruded to films. The polyester and polyamide can also be melted separately and the two melts can be mixed and made into film. Subsequently, the film can be slit to the desired width and the resulting ribbons are drawn. It is also possible first to draw the film and then slit the latter into ribbons. Drawing is accomplished preferably at temperatures above 100° C., a suitable drawing ratio is 1:3 to 1:5, but higher draw ratios may be selected. The thickness of the drawn ribbons may vary within relatively wide limits. Thicknesses between 25 and 50 microns are especially suitable.
The tufted carpet is produced according to well-known processes, whereby appropriate backing fabrics of ribbon-shaped material according to the innovation, and conventional latex and pile yarns of polyamide are used. The tufting process as such is known and need not be explained in further detail. The pile material consists of conventional polyamides, such as nylon 6 or nylon 66. Conventional latices can be used as latex. In addition to the backing fabric, also referred to as primary backing, the tufted carpet may have another, heavier, secondary backing which improves the anchoring of the pile yarn and which may, especially, increase the weight of the carpet.
Tufted carpets according to the innovation have a very level appearance, which is of particular benefit in patterned carpets. This improved evenness shows up in patterns obtained by dyeing methods as well as in patterns produced by using tufts of different heights.
The tufted carpet according to the innovation has a high dimensional stability. There is a good bond between latex and backing and pile material. The tufting material according to the innovation is very readily flattened and covered. Difficulties in piece-dyeing in the form of bleeding or non-dyeing of the backing are practically non-existent. The tufted carpet according to the invention can also be dyed directly in the form of long strips on continuous dye equipment. The notorious floating often observed with carpet strips with a polypropylene backing is not encountered.
The invention is illustrated in the following example:
EXAMPLE
A mixture of chips of 80% polyamide and 20% polyethylene terephthalate is dried and a film is cast therefrom using a single-screw extruder with a 400 mm. wide extruding die. Subsequently, the film is slit into ribbons and drawn to a ratio of 1:3.6.
The ribbons serve to weave a backing fabric in plain weave. A greige carpet is produced by the known needle tufting technique by insertion of a polyamide pile material using a Singer Cobble Tufting machine of conventional design and gauge, which greige carpet is then conventionally dyed with acid dyes on a winch vat, then extracted, dried and provided with a coating to anchor the pile, which coating is simultaneously the adhesive for a jute laminate. The tufting support material is dyed the same shade as the pile material.

Claims (5)

What is claimed is:
1. Tufted nylon carpet having a backing of ribbon-shaped warp and filling yarns having a reduced splitting tendency comprising a matrix-fibril structure of a mixture of 65 to 80% by weight polyamide and 20 to 35% by weight polyester, wherein the matrix consists of polyamide and the fibrils, consisting of polyester, are discontinuous.
2. The tufted carpet of claim 1, characterized by warp and filling yarns of a mixture of 70 to 80% by weight polyamide and 20 to 30% by weight polyester.
3. The tufted carpet of claim 2, wherein the length of the fibrils is from 1.5 to about 160 micron and the diameter of the fibrils is from about 0.5 to about 6 microns.
4. The tufted carpet of claim 3, wherein the length of the fibrils is from about 15 to 80 microns and the diameter of the fibrils is from about 0.5 to about 1.5 microns.
5. The tufted carpet of claim 4, wherein the warp and filling yarns contain a delusterant.
US05/676,845 1975-04-16 1976-04-14 Tufted carpet with woven ribbon backing of polyamide and polyester Expired - Lifetime US4010303A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE7512027 1975-04-16
DT7512027[U] 1975-04-16

Publications (1)

Publication Number Publication Date
US4010303A true US4010303A (en) 1977-03-01

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0340992A1 (en) * 1988-05-02 1989-11-08 E.I. Du Pont De Nemours And Company Woven fabric from splittable ribbons
US4906520A (en) * 1988-05-02 1990-03-06 E. I. Du Pont De Nemours And Company Woven fabric from splittable ribbons
US5443881A (en) * 1989-12-27 1995-08-22 Milliken Research Corporation Heat stabilized pile fabric
EP0763617A1 (en) * 1994-03-15 1997-03-19 Duskin Company Limited Shoe-wiping mat
CN1042244C (en) * 1995-09-14 1999-02-24 株式会社达斯金 Shoe-wiping mat for rent
WO2018186961A1 (en) * 2017-04-07 2018-10-11 Milliken & Company Washable floor mat with reinforcement layer

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3317366A (en) * 1962-05-18 1967-05-02 Beaunit Corp Woven polyester carpet backing and tufted carpet incorporating the same
US3542632A (en) * 1969-02-28 1970-11-24 Standard Oil Co Fibrillated fabrics and a process for the preparation thereof
US3613612A (en) * 1965-05-05 1971-10-19 Thiokol Chemical Corp High-strength tufted pile fabric
US3864195A (en) * 1972-01-27 1975-02-04 Henry G Patterson Stable synthetic carpet backing material

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3317366A (en) * 1962-05-18 1967-05-02 Beaunit Corp Woven polyester carpet backing and tufted carpet incorporating the same
US3613612A (en) * 1965-05-05 1971-10-19 Thiokol Chemical Corp High-strength tufted pile fabric
US3542632A (en) * 1969-02-28 1970-11-24 Standard Oil Co Fibrillated fabrics and a process for the preparation thereof
US3864195A (en) * 1972-01-27 1975-02-04 Henry G Patterson Stable synthetic carpet backing material

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0340992A1 (en) * 1988-05-02 1989-11-08 E.I. Du Pont De Nemours And Company Woven fabric from splittable ribbons
US4906520A (en) * 1988-05-02 1990-03-06 E. I. Du Pont De Nemours And Company Woven fabric from splittable ribbons
US5443881A (en) * 1989-12-27 1995-08-22 Milliken Research Corporation Heat stabilized pile fabric
US5567257A (en) * 1989-12-27 1996-10-22 Milliken Research Corporation Method for forming heat stabilized pile fabric
EP0763617A1 (en) * 1994-03-15 1997-03-19 Duskin Company Limited Shoe-wiping mat
US5680826A (en) * 1994-03-15 1997-10-28 Duskin Co., Ltd. Shoe-wiping mat for rent
CN1042244C (en) * 1995-09-14 1999-02-24 株式会社达斯金 Shoe-wiping mat for rent
WO2018186961A1 (en) * 2017-04-07 2018-10-11 Milliken & Company Washable floor mat with reinforcement layer
CN110536983A (en) * 2017-04-07 2019-12-03 美利肯公司 Ground cushion is washed with enhancement layer
AU2018249356B2 (en) * 2017-04-07 2021-03-11 Milliken & Company Washable floor mat with reinforcement layer

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